How to Build a Wood Box That Looks Like a Pirate Trunk
- 1). Adjust the table saw to prepare it for cutting 1/2 inch deep, 1/2 inch wide teeth. Attach multiple blades so that the cutting surface is 1/2 inch wide, and adjust the height of the blade to 1/2 inch by turning the wheel to adjust the blade height. The blades will extend 1/2 inch above the top of the table.
- 2). Cut similar size teeth into opposite sides of the 16 inch by 16 inch side boards and the 16 inch sides of the 24 inch by 16 inch end boards. The teeth interlock with the teeth of the boards they connect with when building the box. The first cut on the 16 inch squares is at the bottom of the sides, then 1/2 inch after that is left uncut, followed by another 1/2 inch cut, repeating up the entire edge. The sides of the 24 inch by 16 inch boards begins with 1/2 inch of uncut wood at the bottom, followed by a cut, then another 1/2 inch uncut, repeating until the top of the board.
- 3). Glue the sides of the box to the ends of the box. The teeth will fit into each other smoothly, as every portion of the square sides that was cut corresponds with a section of the front or back that was uncut, and every section of uncut side corresponds with a cut in the front and back. Secure in place with clamps to dry.
- 4). Glue the 25 inch by 13 inch board inside the walls of the box to serve as the bottom of the box.
- 5). Cut the 18 inch by 17 inch plank into two 17 inch by 9 inch planks.
- 6). Draw the sides of the lid onto each of the halves from step 4. The sides consist of a half circle with an 8 inch diameter atop a 1 inch strip of wood. The 1 inch strip of wood will be the full 17 inches, whereas the circle is only 16 inches, centered along the wood. As a result, the 1 inch strip extends 1/2 inch beyond the circle on both sides.
- 7). Cut out the sides using a jigsaw.
- 8). Cut a tooth into the bottom of both sides of the lid, on both ends of each side, for a total of 4 cuts. Cut a tooth out of the tops of both sides of both pieces of 24 inch by 1 inch wood as well. Each tooth will be 1/2 inch wide and 1/2 inch deep. As with the prior teeth on the sides of the box, the teeth from the lid's sides will fit with the teeth on the 24 inch planks, as the section where wood was not cut on the sides matches where wood was removed on the planks, and vice versa.
- 9). Glue the sides of the lid to the 24 inch by 1 inch strips.
- 10
Attach a 24 inch by 2 inch plank to the top of the arc of the lid using a pair of brads. - 11
Attach a second plank, so that it touches the plank from step 9. Use a block plane to file the end touching the first plank down, for flush contact. You want the planks to fit together, but they don't have to be perfect, as a pirate chest should look slightly imperfect. - 12
Continue adding the planks until the top of the lid is fully in place. - 13
Sand the top of the lid to a smooth finish. - 14
Attach the lid to the box with a pair of hinges. Hinges come with their own mounting screws, usually two for each half of the hinge, for a total of 4 per hinge. They screw in with the use of a common screwdriver.
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